Sheet of smokeable material

ABSTRACT

The present invention relates to a laminate (10) comprising a layer of tobacco material (14) and a support sheet (12), wherein the layer of tobacco material (14) has a rough surface so as to provide a permeable structure through which air may be drawn when the laminate (10) is rolled or folded. The present invention also relates to a method of manufacturing a laminate (10), a package comprising a laminate (10), use of a laminate (10) to prepare a smoking article (20), and a smokeable product comprising a laminate (10).

FIELD OF THE INVENTION

The present invention relates to a sheet of smokeable material.

BACKGROUND

Roll your own tobacco products are tobacco products, such as smoking articles, which are prepared by the consumer.

SUMMARY

According to a first aspect of the invention, there is provided a laminate comprising a layer of tobacco material and a support sheet, wherein the layer of tobacco material has a rough surface so as to provide a permeable structure through which air may be drawn when the laminate is rolled or folded.

In some embodiments, the tobacco material comprises fibrous material.

In some embodiments, the fibrous material comprises tobacco.

In some embodiments, the tobacco material comprises reconstituted tobacco.

In some embodiments, the support sheet comprises paper.

In some embodiments, the tobacco material additionally comprises glycerol, polyethylene glycol, and/or propylene glycol.

In some embodiments, the tobacco material comprising from about 5 wt % water to about 20 wt % water, preferably from about 12 wt % water to about 16 wt % water.

In some embodiments, the permeable structure is uniform across the entire thickness of the tobacco material.

In some embodiments, a portion of the support sheet extends beyond an edge of the layer of tobacco material.

In some embodiments, the portion of the support sheet extending beyond an edge of the layer of tobacco material does not extend along the full length of the layer of tobacco material.

According to a second aspect of the invention, there is provided a method of manufacturing a laminate according to the first aspect of the invention, the method comprising the steps of preparing a layer of tobacco material having a rough surface and adhering the layer of tobacco material to a support sheet.

In some embodiments, the layer of tobacco material according to the second aspect of the invention comprises fibrous material.

In some embodiments, the fibrous material comprises tobacco.

According to a third aspect of the invention, there is provided a package containing a laminate according to the first aspect of the invention.

According to a fourth aspect of the invention, there is provided the use of a laminate according to the first aspect of the invention to prepare a smoking article.

According to a fifth aspect of the invention, there is provided a smokeable product comprising a laminate according to the first aspect of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 shows a cross section of a laminate according to the present disclosure.

FIG. 2 shows a perspective view of a smoking article formed from a laminate according to the present disclosure.

FIG. 3 shows a laminate according to the present disclosure.

DETAILED DESCRIPTION

Conventional roll your own tobacco products are prepared by the user through the use of loose cut tobacco and rolling paper. The consumer typically measures out cut tobacco, spreading it evenly along the length of the paper, forming a channel with the paper such that the tobacco is contained in the bottom of the channel, manipulating the tobacco by rolling paper between the fingers and thumbs to form a substantially cylindrical rod of tobacco, rolling the paper around the tobacco and sticking a free edge of the paper to the outer surface of the cylindrical article that is produced to form a smokeable cigarette. This method of forming a cigarette requires separate handling of tobacco and papers and results in cigarettes with varying quantities of tobacco. This provides the consumer with an inconsistent smoking experience. In addition, there is also risk of losing tobacco through spillage due to the separate handling of the tobacco and papers.

Roll your own tobacco products have also been proposed where a paper is provided with a layer of tobacco adhered to one side of the paper. However, these pre-charged papers do not always provide the user with a consistent smoking experience. For example, a pre-charged paper may be folded or rolled more or less tightly. Therefore, the resistance to draw may vary from one smoking article to the next.

The laminate according to the present invention comprises a layer of tobacco material and a support sheet. The layer of tobacco material comprises a rough surface so as to provide a permeable structure through which air may be drawn when the laminate is rolled or folded into a smoking article. When the laminate is rolled or folded at least some of the surface of the layer of tobacco material contacts the support sheet. The presence of the rough surface provides channels either through the tobacco material or between the tobacco material and the adjacent support sheet through which air may be drawn.

As used herein, “tobacco material” refers to any smokeable material and includes, but is not limited to any part, e.g. leaves, leaf portions, flowers, roots, and stems, of any member of the genus Nicotiana and blends thereof, reconstituted tobacco, tobacco substituents, tobacco derivatives, dried fruits or herbs, and the like. In some embodiments, the tobacco material comprises reconstituted tobacco.

The layer of tobacco material has a rough surface. For example, the layer of tobacco material may be described as having an uneven or irregular surface. The rough surface may be formed when preparing the layer of tobacco material. For example, pressing the layer of tobacco material either longitudinally or laterally may provide a rough surface. For example, strands of tobacco material may be laid onto the paper and compressed, forming an irregular surface.

In some embodiments, the rough surface may be created by the presence of a fibrous material. For example, larger particles or fibres may be distributed either uniformly or randomly across the surface of the layer of tobacco material to provide a rough surface comprising a series of channels or pathways within the tobacco material through which air may pass. These pathways may be within the layer of tobacco material or they may be formed between the surface of the tobacco layer and an adjacent layer when rolled or folded. Alternatively, relatively larger particles of fibres may be present within the layer of tobacco material. Their greater size prevents the tobacco material from forming a smooth surface and therefore creates a rough surface. The fibrous material may be from a cellulosic source, such as tobacco, reconstituted tobacco (including, for example, so called Fibex), wood or paper, waste lamina, or other sheet material such as smokeable filler material comprising a blend of non-combustible inorganic filler material, a binder, and an aerosol generating means. Most preferably, the fibrous material comprises a smokeable material, such as cut stems of tobacco.

In some embodiments, the tobacco material may be flexible in order for the laminate to be rolled or folded without the layer of tobacco material cracking, splintering or in any other way separating from the support sheet. For example, the layer of tobacco material may comprise an additive which enables the layer of tobacco material to be manipulated on the support sheet without breaking. In particular, various gums and pectins may be used as a binder when preparing the layer of tobacco material to assist with maintaining the integrity of the layer of tobacco material. Preferred binders are natural pectins, such as fruit, citrus, tobacco pectins, guar gums such as hydroxyethyl guar and hydroxypropyl guar, locust bean gums, such as hydroxyethyl and hydroxypropyl locust bean gum, alginate, starches, such as modified or derivitised starches, celluloses, such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose, tamarind gum, dextran, pullalon, konjac flour, xanthan gum, and the like.

In some embodiments, the tobacco material may additionally contain water. When a reconstituted tobacco material contains water as an additive, the tobacco material is more flexible. For example, the tobacco material may contain from about 5 wt % water to about 20 wt % water. Preferably, the tobacco material contains from about 12 wt % water to about 16 wt % water.

In other embodiments, the layer of tobacco material may comprise further additional additives, such as flavours and/or flavourants. As used herein, the terms “flavour” and “flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers. They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, cacao, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

In some embodiments, the layer of tobacco material may comprise a humectant, such as glycerol, polyethylene glycol, and propylene glycol.

In some embodiments, the rough surface may extend across the entire thickness of the layer of tobacco material. When the rough surface extends across the entire thickness of the layer of tobacco material, the rough surface provides a minimum resistance no matter how tightly the laminate is rolled or folded. In some embodiments, the rolled laminate provides low draw resistance for consumer preference.

In some embodiments, the pressure drop of the rolled laminate is from about 30 mm WG (Water Gauge) to about 200 mm WG. Preferably, the pressure drop is from about 95 mm WG to about 155 mm WG. In some embodiments, the pressure drop is 0.2 to 1.5 mm WG per mm length of the rolled laminate, preferably 0.5 to 1.0 mm WG per mm.

In some embodiments, the thickness of the layer of tobacco material is from about 0.5 mm to about 3 mm.

In addition to the layer of tobacco material, the laminate comprises a support sheet. As used herein, “sheet” is intended to refer to any material suitable for supporting tobacco and capable of being wrapped around itself. The support sheet may be made from any sheet suitable for circumscribing a tobacco rod of a smoking article. In some embodiments, the support sheet may comprise paper. Examples include, but are not limited to, standard wrapping paper as used for roll your own or pre-formed cigarettes and reconstituted tobacco sheets. The material may have a papery texture, or it may feel rough, moist or be otherwise distinguishable from standard papery textures. For example, the support sheet may be a sheet comprising any reconstituted material, including reconstituted tobacco material, or a sheet comprising chalk, or a sheet comprising a blend of inorganic filler material, binder, and aerosol generating means.

In some embodiments, the layer of tobacco material covers the whole area of the support sheet except for at least one strip which is free of tobacco. Preferably, the tobacco free strip is located close to or along an edge. In some embodiments at least one of these tobacco-free edges may have an adhesive applied thereto. In some embodiments, the laminate is rolled to form a smoking article. When the laminate is rolled the tobacco free area along the edge of the support sheet may be adhered to the outside surface of the smoking article to retain the laminate in a substantially cylindrical configuration.

In some embodiments, the layer of tobacco material may cover the whole area of the support sheet except a strip located along the longitudinal edge. When a tobacco free strip is located along the longitudinal edge, the laminate may be more easily rolled into a smoking article.

In some embodiments, a pack is provided containing at least one laminate according to the present invention. For example, a pack may contain numerous laminates which can be rolled or folded into a smoking article. In some embodiments, laminates may be provided in individually sealed wrappers. When a laminate is kept within an individual wrapper, the moisture within the wrapper may be optimised. For example, the moisture within the wrapper can be from about 5 wt % water to about 20 wt % water, preferably from about 12 wt % water to about 16 wt % water. The internal atmosphere of the individual wrapper may be selected to ensure that the layer of tobacco material remains fresh and to maintain a desired moisture content so that the laminate can be rolled or folded whilst maintaining its structural integrity. In order to retain the optimised moisture content of the laminate, the laminate can be provided in a modified atmosphere wrapper in order to keep the aroma and texture similar to a conventional roll your own cigarette.

In some embodiments, the laminate may comprise an additional removable layer located on the support sheet. For example, the laminate may have a removable tear off which exposes an adhesive when removed from the support sheet. In some embodiments, a removable protective sheet may prevent tobacco material being lost from the layer of tobacco material during transportation and storage. In addition, the protective sheet may help to prevent the degradation of the layer of tobacco material, thus ensuring that the laminate may be rolled or folded as desired by the user.

In some embodiments, the laminate may include a layer of tobacco material which is positioned to allow the laminate to receive a filter plug when rolled or folded. For example, the layer of tobacco material may not extend to the edge of the support sheet. In particular, one edge of the laminate sheet may be shaped to form a cavity to receive a filter plug when the laminate is rolled or folded. In this instance, when the laminate is rolled or folded, the user may position a filter plug in this tobacco free region. Rolling or folding the laminate around a filter plug provides the user with a smoking article.

In another embodiment, the rolled laminate may be smoked in the absence of a filter plug.

In another embodiment, the laminate may be used in a “make your own” type tobacco industry product, a cigarillo, Glo, or any other suitable tobacco industry product.

A laminate 10 is shown in FIG. 1. The laminate 10 comprises a support sheet 12 and a layer of tobacco material 14.

As shown in FIG. 2, when rolled, the laminate 10 forms a smoking article 20.

FIG. 3 shows a laminate 10 comprising a support sheet 12, a layer of tobacco material 14, and a tobacco free region 16 of support sheet 12. Such a laminate allows a filter plug to be positioned in the tobacco free region 16 when preparing a smoking article. When rolled the tobacco free region shall form a hollow tube to receive a filter plug.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide a roll your own tobacco product. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future. 

1. A laminate comprising a layer of tobacco material and a support sheet, wherein the layer of tobacco material has a rough surface so as to provide a permeable structure through which air may be drawn when the laminate is rolled or folded.
 2. A laminate according to claim 1, wherein the tobacco material comprises fibrous material.
 3. A laminate according to claim 2, wherein the fibrous material comprises tobacco.
 4. A laminate according to claim 1, wherein the tobacco material comprises reconstituted tobacco.
 5. A laminate according to claim 1, wherein the support sheet comprises paper.
 6. A laminate according to claim 1, wherein the tobacco material additionally comprises glycerol, polyethylene glycol, and/or propylene glycol.
 7. A laminate according to claim 1, wherein the tobacco material comprises from about 5 wt % water to about 20 wt % water.
 8. A laminate according to claim 1, wherein the permeable structure is uniform across an entire thickness of the tobacco material.
 9. A laminate according to claim 1, wherein a portion of the support sheet extends beyond an edge of the layer of tobacco material.
 10. A laminate according to claim 9, wherein the portion of the support sheet extending beyond an edge of the layer of tobacco material does not extend along the full length of the layer of tobacco material.
 11. A method of manufacturing a laminate according to claim 1, the method comprising preparing a layer of tobacco material having a rough surface and adhering the layer of tobacco material to a support sheet.
 12. A method according to claim 11, wherein the layer of tobacco material comprises fibrous material.
 13. A method according to claim 12, wherein the fibrous material comprises tobacco.
 14. A package containing a laminate according to claim
 1. 15. A laminate according to claim 1, wherein the laminate is configured to prepare a smoking article.
 16. A smokeable product comprising a laminate as defined in claim
 1. 17. A laminate according to claim 1, wherein the tobacco material comprises from about 12 wt % water to about 16 wt % water. 